White Label Gyratory Crusher Brochure
1. PAINPOINT DRIVEN OPENING
Are escalating operational costs and unpredictable availability eroding your primary crushing circuit’s profitability? Key challenges in gyratory crusher operations often include:
Unscheduled Downtime: Premature wear of critical components like mantles and concaves leads to failure, causing costly, unplanned production halts.
High Maintenance Complexity: Traditional designs require extensive labor hours for routine inspections and liner changes, keeping your skilled technicians occupied instead of on proactive tasks.
Inconsistent Product Gradation: Worn or poorly configured crushing chambers yield offspec product, creating bottlenecks for downstream processes and reducing plant throughput.
Excessive Energy Consumption: Inefficient crushing action and highfriction designs result in disproportionate power draw per ton of material processed.
What if your primary crusher could deliver higher throughput with greater reliability, while reducing both your maintenance burden and cost per ton? The solution requires a design focused on durability, serviceability, and process efficiency.
2. PRODUCT OVERVIEW
The White Label Gyratory Crusher is a heavyduty, primary compression crusher engineered for the first stage of reducing runofmine ore or quarry rock. It is designed for hightonnage, continuous operation in fixedplant applications.
Operational Workflow:
1. Feed: Large feed material (typically up to 1.5m in size) is delivered via dump trucks or a primary feeder into the topmounted feed hopper.
2. Crushing: The central gyrating mantle eccentrically compresses material against the stationary concave, fracturing rock through progressive cycles of compression.
3. Discharge: Crushed product gravitates downward through the narrowing chamber until it reaches the desired size and exits through the discharge opening at the bottom.
Application Scope: Ideal for highcapacity (2,000 10,000+ tph) mining of metal ores (copper, iron, gold) and largescale aggregate quarries requiring consistent, coarse output.
Limitations: Not suitable for lowtonnage operations (<500 tph), abrasive recycling materials (e.g., concrete with rebar), or applications requiring frequent relocation.
3. CORE FEATURES
Patented Concave Design | Technical Basis: Segmented, reversible alloy steel liners | Operational Benefit: Extends service life by up to 30% and allows for rotation of wear parts to utilize full profile | ROI Impact: Reduces liner inventory costs and frequency of changeouts, lowering cost per ton
Integrated Smart Chamber Control | Technical Basis: Realtime hydraulic adjustment and monitoring of the main shaft position | Operational Benefit: Enables operators to optimize product size and crusher load without stopping operation | ROI Impact: Maintains target gradation for downstream efficiency; prevents overload damage
TopService Design | Technical Basis: All maintenance points accessible from above via a central service platform | Operational Benefit: Enables safe removal of the mantle and concaves without dismantling the lower frame or feed hopper | ROI Impact: Reduces planned liner change downtime by approximately 40%
Hydroset® Tramp Release System | Technical Basis: Hydraulically supported main shaft with automated pressure sensing | Operational Benefit: Automatically lifts the mantle to release tramp metal or uncrushable material, then resumes prior setting | ROI Impact: Eliminates damage from uncrushables; prevents major mechanical failure and associated repair costs
HighEfficiency Drive System | Technical Basis: Direct Vbelt drive with highinertia flywheels and lowfriction bearings | Operational Benefit: Provides smooth power transmission with reduced mechanical losses under fluctuating loads | ROI Impact: Field data shows a 58% reduction in specific energy consumption (kWh/ton) compared to legacy geardriven systems
Condition Monitoring Portals | Technical Basis: Hardened access points with integrated sensor ports for oil analysis, vibration, and temperature | Operational Benefit: Facilitates predictive maintenance by allowing easy sampling and data collection during operation | ROI Impact: Shifts maintenance strategy from reactive to predictive, maximizing component life
4. COMPETITIVE ADVANTAGES
| Performance Metric | Industry Standard Average | White Label Gyratory Solution Documented Performance | Advantage (% Improvement) |
| : | : | : | : |
| Liner Change Time (Major) | 24 36 hours
for similar size class
| <16 hours
via topservice design
| ~40% faster |
| Specific Energy Consumption
(kWh per metric ton) | Varies by material; Baseline = X kWh/t | X 0.08X kWh/t
via optimized drive & chamber
| 58% reduction |
| Annual Availability
(Scheduled & Unscheduled) | 92 94% | >96%
per fleet telemetry data
| >2 percentage points |
| Mean Time Between Failure (MTBF)
for Major Components | ~8,000 hours | >10,500 hours
based on bearing & shaft data
| >30% increase |
5. TECHNICAL SPECIFICATIONS
Capacity Range: Configurable from 2,000 to over 12,000 metric tons per hour (tph), dependent on model selection and feed material.
Motor Power: Standard drives from 450 kW to 1,200 kW (600 HP – 1,600 HP). Custom configurations available.
Feed Opening: Gape sizes from 1,050 mm (42”) to 1,500 mm (60”).
Main Frame & Concaves: Fabricated from hightensile steel plate; concaves available in multiple alloy grades (Mn14Cr2 to Mn22Cr3) for optimal wear life vs. cost.
Discharge Setting Range: Hydraulically adjustable from 125 mm to 250 mm (5” – 10”) depending on model.
Operating Temperature Range: Designed for ambient conditions from 40°C to +50°C (40°F to +122°F). Optional lube oil heating/cooling packages available.
Dust Sealing: Multistage labyrinth seals with positivepressure air purge system as standard.
6. APPLICATION SCENARIOS
Copper Mine Expansion – Throughput Constraint
Challenge: A major copper operation needed to increase plant throughput by 20% but was constrained by their existing primary crushing circuit’s capacity limit of ~4,800 tph and frequent concaverelated downtime.
Solution: Installation of a single White Label Gyratory Crusher (60” gape model) with highcapacity concaves and smart chamber control.
Results: Sustained throughput increased to an average of >5,800 tph. Topservice design reduced annual planned maintenance hours by ~200 hours. The project met its expansion throughput target within six months of commissioning.
Granite Aggregate Quarry – Product Quality & Cost
Challenge: An aggregate producer faced inconsistent product cubicity from their older gyratory crusher leading to poor asphalt mix quality. They also experienced high energy costs per ton crushed.
Solution: Replacement with a midrange White Label Gyratory Crusher featuring an optimized chamber profile for aggregate shaping.
Results: Product flakiness index improved by over 15%, meeting premium specification requirements. The new drive system contributed to a documented annual energy saving exceeding $65k based on local power rates.
7. COMMERCIAL CONSIDERATIONS
White Label Gyratory Crushers are offered in three primary tiers based on size class:
1. Performance Tier: For capacities up to ~4，500 tph， includes core features like TopService Design， Hydroset System，and standard monitoring portals。
2 HighCapacity Tier: For operations up to ~8，000 tph， adds Smart Chamber Control as standard， enhanced alloy liners，and upgraded bearing packages。
3 UltraDuty Tier: For maximum throughput (>8，000 tph)， includes full predictive sensor suites， premium metallurgy throughout，and custom discharge configurations。
Optional features include advanced lubrication filtration systems， automated wear measurement probes，and remote telematics integration。
Financing options include capital purchase， longterm leasetoown agreements（3660 months），and certified refurbished units with full warranty。 Comprehensive service packages are available covering scheduled maintenance parts kits（PM Kits），onsite technical support during major services，and guaranteed emergency parts delivery。
FAQ
Q1： Is this equipment compatible with our existing secondary crushing circuit？
A： Yes。 Our engineering team can review your current flow sheet specifications。 The hydraulic adjustment system allows precise control over discharge settings（CSS）to ensure optimal feed gradation for your cone crushers or downstream processes。
Q2： What is the expected operational impact during installation？
A： Installation typically requires a prepared concrete foundation。 We provide detailed foundation drawings。 From delivery of major components到commissioning typically requires an eighttotwelveweek site schedule depending on civil work scope。 We offer supervised installation services。
Q3： How does financing work？
A： We work with several industrial equipment finance partners。 Typical structures require an initial down payment followed by fixed monthly payments。 Lease structures may offer potential tax benefits； we recommend consulting your financial advisor。
Q4： What training is provided？
A： We provide comprehensive operator training covering normal startup/shutdown procedures daily checks troubleshooting basics。 Maintenance team training covers liner change procedures lubrication system management use of condition monitoring tools。
Q5： What are typical lead times？
A： Lead times vary based on model tier customization。 For standard models lead time ranges from six months（Performance Tier）to ten months（UltraDuty Tier）。 We maintain critical spare parts inventory at regional hubs。
Q6： Can you guarantee performance metrics like throughput？
A： We provide performance projections based on standardized laboratory testing results using representative samples you supply。 Final performance depends on sitespecific factors including feed characteristics fragmentation haul truck scheduling which are outside our direct control。
Q7： What is included in the warranty？
A： Our base warranty covers defects in materials workmanship under normal use service periods ranging twelve months from commissioning date twentyfour months total from shipment date whichever occurs first。 Wear parts consumables like liners are covered under separate terms